I have been trying to figure out if I am doing this right before I continue on. I pick one machine that is hook up to a 480v bus that is feed by a Pow-R-Way switchboard, It is feed by 2500kva transformer. There is no fuses or CB between the transformer and switchboard.

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I haven't looked much into the rest of your calculations, but I question the 0.1 sec clearing time on bus one. If this is based on the fuse upstream of the main transformer, then the clearing time is likely to be much longer.

Where are you getting your PPE Levels.
At the main bus you show an IE of 5.6 cals and a Class PPE of 1.
If Class is the same as Level, then it should be Level 2, (4-8 cals).
For IE under 4 cals you are showing Class 0. These should be Level 1.

Category 0 is still in Table 130.7(C)(11) in NFPA 70E-2009 and this would be applicable up to 1.2 cal/cm2. Above 1.2 cal/cm2, FR clothing is required as per Article 130.7(C)(5).

IMHO, I think Table 130.7(C)(11) should have 5 J/cm2 (1.2 cal/cm2) in the Required Minimum Arc Rating of PPE column, not N/A for Category 0. This would make the table consistent with the text in Article 130.7(C)(5).

I need some guidance on calculating BOLTED FAULT CURRENT.
I cannot find out how to get access to IEEE-1584 which I would assume would answer most or all of my questions. I would appreciate advice from anyone wiser than I.
Here is what I have assumed (please correct me where I am wrong).

1. Secondary of my transformer.
2. Wiring impedance all the way to the flash point (as found by using info from my Ã¢â‚¬ËœUglyÃ¢â‚¬â„¢sÃ¢â‚¬â„¢ book pg 66.)
3. Safety factors & K factors which I hope a wise person can inform me of.

Questions:
1. When figuring wiring impedance, do I use Ã¢â‚¬Ëœdistance to flash pointÃ¢â‚¬â„¢ + Ã¢â‚¬Ëœdistance back from flash pointÃ¢â‚¬â„¢ at 460vac OR Ã¢â‚¬Ëœdistance to flash pointÃ¢â‚¬â„¢ only @ 277vac OR some other method?
2. What are Ã¢â‚¬Ëœstandard safety factorsÃ¢â‚¬â„¢ and K factors commonly accepted (if any)?

Identify the type of cable from the transformer secondary to the point of the potential flash location under review. If you are going through multiple gear identify type and distance for each run, and type of raceway. You just need to list for one phase, the other phases are identical. So for example, from transformer to switchboard, 4 parallel 500 MCM copper in EMT x 80 ft. From switchboard to lighting panel (point of flash) 1 each 4/0 Copper in tray cable x 300 feet.

Estimate the total KVA motor load and identifier any synchronous motor or generators.

I take it you don't have software, and you don't need it for small sites. Most of us would probably do this with the 'per unit' method of calculation. But it sounds as if you might need something easier to start with. For arc flash calcs, which only looks at 3 phase bolted fault, I like the MVA method for calculating faults. It follows the V=IR type of equations you seem to prefer.

Go to arcadvisor.com and investigate the method. If you don't find it, contact the owner and ask him for the white paper on the MVA method. If you have a limited number of points, spend the $50 and sign up with him and use his on line software. But let me warn you its a bit quirky until you understand how to use it.

In the back of your NEC book find the table for Conductor Properties, look for the Z impedance values for you cables and type of raceway.

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